Reinforced aluminum shingle

ABSTRACT

A reinforced aluminum shingle which comprises in combination a tapered cedar wood backing and a covering of reinforced aluminum sheet which is cemented to a portion of the surface of the cedar backing. The reinforced aluminum sheet overhangs the thicker edge of the backing in a lip to provide an air gap upon installation which acts to prevent the entrance of water under the shingle.

United States Patent 1191 Chalmers et al [111 3,811,240 Horny May 21, 1974 REINFORCED ALUMINUM SHINGLE 2,935,768 5/1960 Roupe 52/554 1 Inventor Armand 7518 Tabor 1,33??? Z1333 fiilfiingiiii 1::113331113165553? Phfladelphla, P 2,384,686 9/1945 Kl'atlS 52/540 2,847,948 Truitt PP 257,815 Primary Exdminefl-Henry C. Sutherland 6 Assistant ExaminerLeslie A. Braun 52 us. c1 52/560, 52/521, 52/556 Attorney, Agent, or Firm-Karl L1 Spwak [51] Int. Cl E046 l/06, EO4d l/28 [58] Field of Search 52/560, 521, 554-566, [57] ABSTRACT 52/540 3 A reinforced aluminum shingle which comprises in f combination a tapered cedar wood backing and a cov- -[56] Re erences C'ted ering of reinforced aluminum sheet which is cemented UNITED STATES PATENTS to a portion of the surface of the cedar backing. The 2,231,008 2/ l94l Ochs 52/556 X reinforced aluminum sheet overhangs the thicker edge l,6l6,968 2/1927 Hall 52/521 of the backing in a lip to provide an air gap upon inl.5 2,377 2/1926 Blair 52/513 X stallation which acts to prevent the entrance of water 3.347.001 l0/l967 Costen.... 52 521 X under the Shing1e 2,856,647 l0/l958 Beckinan et al. 52/540 3,377,762 4/1968 5.2/555 1 Claim, 5 Drawing Figures azz-2:1 1?? 1 REINFORCED ALUMINUM SHINGLE' BACKGROUND OF THE INVENTION The present invention relates generally to the building construction field, and more particularly, is directed to a composite roofing material which is suitable both for residential and commercial use In the construction of residences, commercial buildings and industrial buildings, it has been the common practice to provide roofing materials of various components suitable to render the structure relatively impervious to the entrance of water which may fall upon the roof in the form of rain or snow. The use of wooden shingles is well-known and such materials have been widely used in the past due primarily to availability, to inexpensive cost, to ease in installation and in their aesthetically pleasing appearance. However, more recently, it has been found that the wooden shake roofs present a considerable fire hazard due to their combustible nature, and accordingly, such roofs have recently deminished in popularity.

More recent workers in the field have developed composite shingles of various materials in an attempt to provide low cost, efficient, easily installed and relatively durable roofs. For example, U.S. Pat. No. 2,847,948 discloses the use of a glass wool or asbestos base which is covered with a metallic sheet. U.S. Pat. No. 2,961,804 discloses the combination of a building board which is covered with a corrosion resistance metallic sheeting. U.S. Pat. No. 3,232,020 discloses the use of wooden shake shingles having an aluminum base to reduce the fire hazard while still retaining the desired external appearance. US. Pat. No. 3,319,390 shows a composite fibre board and vinyl sheeting to simulate a wooden shingle. I

The present invention seeks to improve over the prior art in providing an inexpensive, exceptional strong and easily installed roofing material.

SUMMARY OF THE INVENTION The present invention relates generally to the field of roofing materials, and more particularly, is directed to a composite tapered wooden base shingle which is partially covered with a reinforced aluminum surface.

Preferably, the base is fabricated of cedar wood which tapers from a thickness of approximately onesixteenth of an inch at the upper end to a thickness of approximately three-eighths of an inch at the lower end through a length of approximately 16 inches. If desired, the cedar wood base can be impregnated with a suitable fire retardant chemical. A reinforced aluminum sheet affixes over the top surface of the wood backing and is cemented thereto with a suitable waterproof cement. The reinforced aluminum sheet covers substantially the lower two-thirds of the backing member and overhangs the thickened end of the cedar backing by a distance of approximately one-quarter of an inch. The one-quarter inch overhang thus provides an air gap of three-eighths of an inch between the bottom of the overhanging aluminum lip and the surfaceof the shingle below upon installation, to thereby prevent water from backing up and seeping between the shingles upon use.

The aluminum sheeting is preferably treated for corrosion resistance and is provided with a patterned dimpled surface to provide a plurality of minute arches for shingle strengthening purposes. The reinforced alumi- 2 num sheet provides adequate strength to permit the, roof to be readily walked upon without damage to the shingles after installation.

It is therefore an object of the present invention to provide an improved reinforced aluminum shingle of the type set forth.

It is another object of the present invention to provide a novel reinforced aluminum shingle comprising in combination an insulating, wooden base and a sheet of reinforced aluminum cemented to the top surface of the base.

It is another object of the present invention to provide a novel reinforced aluminum shingle wherein a tapered base member is employed and a covering of reinforced aluminum sheet is cemented to the top surface of the tapered member.

It is a further object of the present invention to provide a novel roofing material which includes in combination a length of tapered, cedar wood shingle and a reinforced aluminum sheet affixed to the top surface of the shingle, the said aluminum sheet overhanging the thicker end of the shingle in a lip of length sufficient to provide an air gap upon installation.

It is a further object of the present invention to provide a novel reinforced aluminum shingle which incorporates the properties of increased strength, better insulation, unlimited life and freedom from maintenance.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view ofa roof ofa home which has been constructed by employing the reinforced shin- I gles of the present invention.

FIG. 2 is an enlargedtop plan view ofa shingle whichv is employed in the roof of FIG. 1.

FIG. 3 is a cross-sectional view taken along Line 3--3 of FIG. 2, lookingin the direction of the arrows.

FIG. 4 is an enlarged, cross-sectional view taken along Line 4-4 of FIG. 2, looking in the direction of the arrows.

FIG. 5 is an enlarged, cross-sectional view taken along Line 5-5 of FIG. 1, looking in the direction of the arrows.

DESCRIPTION OF THE PREFERRED EMBODIMENT OF THEINVENTION Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of my invention selected for illustration in the drawings and are not intended to define or limit the scope of the invention.

Referring now to the drawings, show in FIG. 1, a roof 10 which is covered by reinforced aluminum shingles 12 of the present invention as hereinafter more fully set forth. In accordance with well known techniques of roofing fabrication transverse rows 56, 58 of shingles may be staggered as necessary so..,that each row protects the junction between horizontally butting shingles of the preceding row to thereby provide a complete, waterproof and weather tight roofing surface.

As best seen in FIGS. 2 and 3, each shingle 12 comprises a wooden base 14 which is preferably a cedar shake and an upper protective surface 16 which is fabricated preferably of reinforced sheet aluminum 28. Each shingle is approximately ,16 inches in height and the wooden base 14 tapers at its upper end 16 from a thickness of approximately one-sixteenth of an inch to its lower end 20 which is approximately three-eighths of an inch in thickness. The-bottom surface 22 of the shingle is applied directly over the usual roofing matethe wooden base 14 in a manner to cover substantially the lower two-thirds to three-quarters of the wooden base 14. The unprotected area 36 is fully covered by thegnext upper row of shingles 58 after installation and thickness of material. Relatively thin sheets may be employed for roofing material purposes. Due to the strength added by the plurality of high points 30, the thin sheets have adequate strength to permit roofers and other workers to walk upon the roof surface without permanent deformation, rupture or other damage.

As best seen in FIGS. 3 and 5, the reinforced aluminum sheet 28 cantilevers outwardly from the lower end of the wooden base 14 a distance of approximately one-quarter of an inch to provide a transverse overhanging lip 52. The overhanging lip 52 defines an air gap 54 when in use to discourage water from backing under the bottom surface 22 of each shingle 12.

In use, the shingles 12 are applied to a roof 10 con-' ventionally in transverse rows 56, 58, each upper row 58 overlapping the upper portion of the lower row 56 to provide a water impervious surface. Nails or other fasteners may be driven through the unprotected area 36 ,into the roofing material 24 in the usual manner. As

hereinbefore stated, the upper row 58 overlaps its next so there is no need to cover the entire base 14. The protective surface 16 comprises reinforced sheet aluminum which may be rigidized Alcoa Alclad QQA 250/5,

No'. 2024 T3, as manufactured by Aluminum'Company of America. This product is rolled to a thickness of 0.025 inches and contains a coating of 1050 alloy of 5 percentxthickness to reduce galvanic action. Alclad 2024 sheet material has a tensile strength of 65,000 psi, a yield strength of 45,000

. mately three-thirty-seconds'of an inch. Additionally,

the high points arrange in a plurality of first transversely spaced rows 42 and a plurality of second transversely spaced rows 44 which alternate with the first rows 42. The high points .30 are longitudinally sepa-' rated by longitudinally valleys 46 and by transversely spaced valleys 48. In the embodiment illustrated, the longitudinally separated valleys 46 are approximately one-half inch on center. The transversely spaced valleys 48 are approximately three-sixteenths-of an inch on center.

As best seen in H6. 4, each spaced high points 30 define asmall air space 34 between the top surface 26 of the wooden base 14 and the underside of the reinforced aluminum sheet 28. The air spaces 34 provide dead air pockets which increase the insulating factor of the composite shingle l2 inasmuch as the air retained in the air space '34 acts as' an efficient insulating material. The high points 30 are each similarly arcuately bent as illustrated to provide a plurality of individual arches 50. The plurality of arches 50 which upwardly project in the longitudinally spacedrows 38, 40 and transversely spaced rows 42, 44 greatly increase the strength of the aluminum sheet 28 without a corresponding increase in adjacent lower row 56 a distance which is greater than i the height of the unprotected area 36 so that a'completely reinforced, aluminum sheet protected, final roof surface is thereby provided. Each overhanging lip 52 defines an air space 54 between the under surface of the lip and the top surface of the reinforced sheet aluminum'28 immediatelybeneath of approximately three-eighths ofv an inch. It is contemplated that the shingles 12 will he usually applied to sloping roofs 10 as illustrated, and accordingly, a drop of water (not shown) which rolls off of the overhanging lip 52willfall straight downwardly under impetus of the forces of gravity. The length of overhang of the lip 52 is such that there is no tendency of the 'drop (not shown) to touch or otherwise enter the transverse junction between adjacent rows, 56, 58 of shingles. Accordingly, all water falling on the roof surface will then flow by gravity downwardly to be discharged in the usual manner.

1 claim:

1. A roof structure including reinforced shingles for waterproofing the top surface of a roof by applying the shingles in overlapping transverse rows, wherein the roof slopes downwardly from a top ridge to a lower edge, the combination of A. a wooden base having an upper surface facing away from' the roof'and a lower surface facing toward the roof,

1. said base lower surface having a first part in contact with the top surface of the roof, facing in vthe direction of the top roof ridge,

2. said base having an upper end and a lower end facing in-the direction of the lower edge of the roof, I g

- 3. said base tapering in thickness from its lower end to its upperend; and I B. a protective surface applied to a portion of the upper surface of the base and being formed of material having a thickness less thanthe thickness of the lower end of the base,

1. said protective surface covering a substantial portion of the upper surface to define a protected 'area extending upwardly from the lower end of the base and an unprotected area, said unprotected area extending downwardly from the upper end of the base,

6 2. said protective surface cantilevering outwardly dividual strengthening arches over the entire profrom the lower end to provide a transverse, overtective surface, said arches being elliptical in hanging lip, cross-section, a. the overhanging lip having a thickness equal to 5. the arches projecting upwardly from the upper the thickness of the protective surface, 5 surface and being arranged in longitudinally b the overhanging lip defining an air gap bespaced and transversely spaced rows,

tween the protective surface of the shingles on 6. the unprotected area being covered by the overone overlapping transverse row and the proteclap of the next said transverse row, tive surface of the transverse row immediately 7. the said arches forming a plurality of dead air beneath, the said air gap being equal to the 10 pockets between the upper surface of the base thickness of the base atits lower edge, and the said protective surface,

, 3. said protective surface being mechanically dea. the said dead air pockets being spaced from formed to provide a plurality of ridges and valeach other by the valleys of the protective surleys for strengthening purposes, face.

4. the said ridges forming a plurality of spaced, in- 

1. A roof structure including reinforced shingles for waterproofing the top surface of a roof by applying the shingles in overlapping transverse rows, wherein the roof slopes downwardly from a top ridge to a lower edge, the combination of A. a wooden base having an upper surface facing away from the roof and a lower surface facing toward the roof,
 1. said base lower surface having a first part in contact with the top surface of the roof, facing in the direction of the top roof ridge,
 2. said base having an upper end and a lower end facing in the direction of the lower edge of the roof,
 3. said base tapering in thickness from its lower end to its upper end; and B. a protective surface applied to a portion of the upper surface of the base and being formed of material having a thickness less than the thickness of the lower end of the base,
 1. said protective surface covering a substantial portion of the upper surface to define a protected area extending upwardly from the lower end of the base and an unprotected area, said unprotected area extending downwardly from the upper end of the base,
 2. said protective surface cantilevering outwardly from the lower end to provide a transverse, overhanging lip, a. the overhanging lip having a thickness equal to the thickness of the protective surface, b. the overhanging lip defining an air gap between the protective surface of the shingles on one overlapping transverse row and the protective surface of the transverse row immediately beneath, the said air gap being equal to the thickness of the base at its lower edge,
 3. said protective surface being mechanically deformed to provide a plurality of ridges and valleys for strengthening purposes,
 4. the said ridges forming a plurality of spaced, individual strengthening arches over the entire protective surface, said arches being elliptical in cross-section,
 5. the arches projecting upwardly from the upper surface and being arranged in longitudinally spaced and transversely spaced rows,
 6. the unprotected area being covered by the overlap of the next said transverse row,
 7. the said arches forming a plurality of dead air pockets between the upper surface of the base and the said protective surface, a. the said dead air pockets being spaced from each other by the valleys of the protective surface.
 2. said base having an upper end and a lower end facing in the direction of the lower edge of the roof,
 2. said protective surface cantilevering outwardly from the lower end to provide a transverse, overhanging lip, a. the overhanging lip having a thickness equal to the thickness of the protective surface, b. the overhanging lip defining an air gap between the protective surface of the shingles on one overlapping transverse row and the protective surface of the transverse row immediately beneath, the said air gap being equal to the thickness of the base at its lower edge,
 3. said protective surface being mechanically deformed to provide a plurality of ridges and valleys for strengthening purposes,
 3. said base tapering in thickness from its lower end to its upper end; and B. a protective surface applied to a portion of the upper surface of the base and being formed of material having a thickness less than the thickness of the lower end of the base,
 4. the said ridges forming a plurality of spaced, individual strengthening arches over the entire protective surface, said arches being elliptical in cross-section,
 5. the arches projecting upwardly from the upper surface and being arranged in longitudinally spaced and transversely spaced rows,
 6. the unprotected area being covered by the overlap of the next said transverse row,
 7. the said arches forming a plurality of dead air pockets between the upper surface of the base and the said protective surface, a. the said dead air pockets being spaced from each other by the valleys of the protective surface. 